Magnetic pulse actuation arrangement having a reluctance reduction configuration and method

ABSTRACT

A magnetic pulse actuation arrangement including an inductor, a workpiece spaced from the inductor, a reluctance reduction configuration in magnetically operable communication with the inductor and the workpiece. Also included is a method for completing a borehole including running an arrangement as in any prior embodiment into the borehole, configuring the arrangement to reduce reluctance, generating a magnetic pulse, and moving a workpiece.

BACKGROUND

Applicants refer to U.S. Ser. No. 62/374,150, incorporated herein by reference, where a magnetic pulse actuation system is first disclosed. Such systems function well allowing an operator to move a workpiece to a desired position and condition. Power requirements for the system are relatively high and hence the art would appreciate improvements that reduce such requirements.

BRIEF DESCRIPTION

A magnetic pulse actuation arrangement including an inductor, a workpiece spaced from the inductor, a reluctance reduction configuration in magnetically operable communication with the inductor and the workpiece.

A method for completing a borehole including running an arrangement as in any prior embodiment into the borehole, configuring the arrangement to reduce reluctance, generating a magnetic pulse, and moving a workpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 depicts a schematic cross sectional view of a magnetic pulse actuation system including an embodiment of reluctance reduction as disclosed herein;

FIG. 2 depicts a field saturation graph illustrating field saturation without and with the reluctance reduction hereof;

FIG. 3 depicts a schematic cross sectional view of a magnetic pulse actuation system including another embodiment of reluctance reduction as disclosed herein; and

FIG. 4. depicts a cross section view of FIG. 3 taken along section line 4-4.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

In connection with the present disclosure, applicant's use of the term “pulse” relates to a magnetic field that is rapidly formed and will accelerate a workpiece to a minimum of 200 meters per second wherein the term “pulse” itself is defined by its ability to cause the workpiece to achieve the minimum velocity stated for an unspecified period of time and by ensuring an excitation pulse frequency range is within +/−150% of the natural frequency of the workpiece to be accelerated. Various actuations described herein are achievable using the pulse as defined for differing lengths of time such as installing a tool in the downhole environment, moving a portion of a tool (moving the workpiece), etc.

Generally applicable to all of the embodiments hereof, the pulse occurs pursuant to the use of an inductor attached to a power source that may be a capacitor bank in some embodiments. Release of a high amplitude and high frequency current as the pulse defined above from the power source at a selected time generates a high-density magnetic field pulse that is coupled to a workpiece placed in the vicinity thereof. An eddy current will consequently be produced in the workpiece with a field orientation that opposes the current induced field hence providing a magnetic pressure that is capable of accelerating the workpiece in a direction. Duration of a given pulse equates to distance of movement for a given system.

Referring to FIG. 1, one embodiment of a magnetic pulse actuation arrangement 10 having a reluctance reduction configuration is illustrated. The arrangement includes an inductor 12 fed by a power source 14 such as a capacitor. The capacitor 14 may be a source of electrical energy or may be used to condition electrical energy from another source such as a battery (not shown) or cable from a more remote location (not shown). A workpiece 16 is disposed near the inductor 12 such that a magnetic field produced by the inductor is coupled to the workpiece 16 generating a magnetic pulse to move the workpiece. The magnitude of the magnetic pulse is proportionally related to the current applied to the inductor. The velocity of movement of the workpiece under the influence of the magnetic pulse is, as noted above, at a minimum velocity of 200 meters per second.

Movement of the workpiece is adjustable from merely a positional change without impacting another structure to an impact with another structure 18 such as a casing in FIG. 1 at such velocity that plastic deformation of the workpiece 16 occurs at an energy level where a bond (including anywhere from a frictional engagement to a chemical bond to a fusion of base materials) is formed between the workpiece 16 and the structure 18. Careful control of the duration of the magnetic pulse allows control of whether the movement will produce a no contact with another structure, where the workpiece may simply be in contact with the other structure such that movement of the workpiece relative to the structure 18 is impeded but fluid passage is not prevented, where a sufficient pressure seal for a particular operation is without a bond is created (a type of V0 seal) or where a fully welded interface is created by an impact sufficient to cause a material jet and a solid state bond.

Movement may be in a directly radial direction whether inwardly or outwardly or movement may be directed axially or in any other direction selected and in which direction the pulse may be directed. As shown in the depiction of FIG. 1, movement is radially outwardly directed. Movement directed radially is suitable for installing a number of downhole tools that utilize radial displacement such as liner hangers, liner top packers, or casing patches (suitably illustrated in generic FIG. 1) where the workpiece is the liner hanger or the casing patch for example, screens, fishing tools, couplings, plugs, etc.

In each embodiment of magnetic pulse actuation, the power requirements are related to a number of factors including reluctance of the system. Applicants have discovered that reluctance of the systems disclosed and contemplated can be reduced to the benefit of reducing power requirements while boosting magnetic field integrity and saturation thereby improving the function and efficiency of systems employing a reluctance reduction configuration as taught herein.

Referring still to the embodiment of FIG. 1, it will be appreciated that a magnetic gap 20 between the inductor 12 and the workpiece 16 will ordinarily give rise to a fair amount of reluctance. To some extent, the gap itself is difficult to reduce due to functional and manufacturing tolerances of various tools. Reduction of the reluctance is however possible by introducing into the gap 20 a reluctance reduction configuration 22 such as a magnetically permeable material 22, for example one containing magnetic particles, such as a magnetorheological fluid. Material 22 may be a flowable solid or a liquid having properties of high relative magnetic permeability (above 1 using SI units). In one embodiment material 22 is a fluid disclosed in U.S. Pat. No. 5,879,580 and US application number US20100164303A1 incorporated by reference herein in its entirety and available commercially under such trade names as EMG Series FerroFluids by Ferrotec. It is to be understood that the fluid may be resident in the arrangement 10 (carried therein) or may be supplied to the arrangement 10 when needed, the fluid being pumped in the form of a pill from surface or supplied from a storage location proximate a target area for the arrangement, or the fluid simply being in the borehole fluid such that running the arrangement into the fluid while allowing the fluid to move into the arrangement can configure the arrangement for the reduced reluctance.

Referring to FIG. 2, a graph of magnetic field saturation in the gap 20 is illustrated to be markedly denser in systems as taught herein having a reluctance reduction configuration. Evident to readers should be that the resulting magnetic pressure generated by the magnetic pulse will be greater where there is a reluctance reduction configuration because there is a proportional relationship between relative magnetic permeability and the pressure generated by the pulse.

Referring to FIGS. 3 and 4, another embodiment of a magnetic pulse actuation arrangement 40 having a reluctance reduction configuration 42 is illustrated. In this embodiment the reluctance reduction configuration is a mechanical configuration where a magnetically permeable solid material 44 is shifted in position at an appropriate time to physically reduce a gap 46 between an inductor 48 disposed about a mandrel 50 and a workpiece 52. When it is desired to employ the magnetic pulse actuator, the material 44 is moved from a storage position (illustrated in solid lines in FIG. 3, 44 a) to an active position (illustrated in dashed lines in FIG. 3, 44 b). It will be appreciated that the shifting may be by hydraulic, electrical, chemical, magnetic, or mechanical force and is aided in one embodiment by a cone 54. In embodiments, the material 44 may be a complete ring of deformable material (e.g. elastomeric material, a more ductile metal, plastic, etc.) or a split ring in construction where formed of more rigid material (e.g. steel, etc.) to enable the radial growth evident between the storage position, 44 a and the active position, 44 b in FIG. 3. This is easily appreciated in FIG. 4 which is a cross sectional view of FIG. 3 taken along section line 4-4 and when the reluctance reduction configuration is in the active 44 b position. A split 56 is visible in this FIG. 4 caused by the hoop stress acting on the configuration 44 due to the cone 54. The split 56 does allow a small amount of reluctance to persist in that location but relative to the overall reluctance reduction, the split is a minimal detractor. In the embodiments where the ring is complete, no loss in reluctance reduction is experienced.

During use, the arrangement 40 may be run to target and used (first embodiment with configuration in place) or shifted (second embodiment) and then used both of which provide for more efficient and powerful actuation.

Further contemplated herein is a method for completing a downhole system wherein a borehole extends into a formation, a casing 18 is disposed therein and a magnetic pulse actuation arrangement 10, 40 is run into the hole to a target depth. The arrangement 10, 40 is configured for reluctance reduction as taught herein and a magnetic pulse is generated to move a workpiece 16, 52 from a run in position to a final position relative to the casing 18.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A magnetic pulse actuation arrangement including an inductor, a workpiece spaced from the inductor, a reluctance reduction configuration in magnetically operable communication with the inductor and the workpiece.

Embodiment 2

The arrangement as in any prior embodiment wherein the configuration is a magnetically permeable fluid.

Embodiment 3

The arrangement as in any prior embodiment wherein the fluid is a liquid.

Embodiment 4

The arrangement as in any prior embodiment wherein the fluid is a magnetorheological fluid.

Embodiment 5

The arrangement as in any prior embodiment wherein the fluid has a relative magnetic permeability greater than 1.

Embodiment 6

The arrangement as in any prior embodiment wherein the fluid is maintained within the arrangement.

Embodiment 7

The arrangement as in any prior embodiment wherein the fluid is pumped in the form of a pill to the arrangement.

Embodiment 8

The arrangement as in any prior embodiment wherein the fluid is stored proximate a target location and supplied to the arrangement.

Embodiment 9

The arrangement as in any prior embodiment wherein the configuration is a magnetically permeable solid.

Embodiment 10

The arrangement as in any prior embodiment wherein the solid is a ring.

Embodiment 11

The arrangement as in any prior embodiment wherein the arrangement includes a cone interactive with the configuration.

Embodiment 12

A method for completing a borehole including running an arrangement as in any prior embodiment into the borehole, configuring the arrangement to reduce reluctance, generating a magnetic pulse, and moving a workpiece.

Embodiment 13

The method as in any prior embodiment wherein the generating includes saturating a magnetic field between the inductor and the workpiece.

Embodiment 14

The method as in any prior embodiment wherein the configuring includes carrying a magnetically permeable fluid with the arrangement.

Embodiment 15

The method as in any prior embodiment wherein the configuring includes supplying a magnetically permeable fluid to the arrangement in the borehole.

Embodiment 16

The method as in any prior embodiment wherein the configuring includes storing a magnetically permeable fluid near a target area and supplying the magnetically permeable fluid to the arrangement.

Embodiment 17

The method as in any prior embodiment wherein the configuring is shifting a reluctance reduction configuration.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 

What is claimed is:
 1. A magnetic pulse actuation arrangement comprising: an inductor; a workpiece spaced from the inductor; a reluctance reduction configuration in magnetically operable communication with the inductor and the workpiece.
 2. The arrangement as claimed in claim 1 wherein the configuration is a magnetically permeable fluid.
 3. The arrangement as claimed in claim 2 wherein the fluid is a liquid.
 4. The arrangement as claimed in claim 2 wherein the fluid is a magnetorheological fluid.
 5. The arrangement as claimed in claim 2 wherein the fluid has a relative magnetic permeability greater than
 1. 6. The arrangement as claimed in claim 2 wherein the fluid is maintained within the arrangement.
 7. The arrangement as claimed in claim 2 wherein the fluid is pumped in the form of a pill to the arrangement.
 8. The arrangement as claimed in claim 2 wherein the fluid is stored proximate a target location and supplied to the arrangement.
 9. The arrangement as claimed in claim 1 wherein the configuration is a magnetically permeable solid.
 10. The arrangement as claimed in claim 9 wherein the solid is a ring.
 11. The arrangement as claimed in claim 1 wherein the arrangement includes a cone interactive with the configuration.
 12. A method for completing a borehole comprising: running an arrangement as claimed in claim 1 into the borehole; configuring the arrangement to reduce reluctance; generating a magnetic pulse; and moving a workpiece.
 13. The method as claimed in claim 12 wherein the generating includes saturating a magnetic field between the inductor and the workpiece.
 14. The method as claimed in claim 12 wherein the configuring includes carrying a magnetically permeable fluid with the arrangement.
 15. The method as claimed in claim 12 wherein the configuring includes supplying a magnetically permeable fluid to the arrangement in the borehole.
 16. The method as claimed in claim 12 wherein the configuring includes storing a magnetically permeable fluid near a target area and supplying the magnetically permeable fluid to the arrangement.
 17. The method as claimed in claim 12 wherein the configuring is shifting a reluctance reduction configuration. 